Applying Stack-up Methodology to Analyze Compression Ratio Variation on E100 Flex Engines

In internal combustion engines, mainly the Brazilian flex fuel versions, the compression ratio is an important factor to ensure its correct operation, and especially to ensure that the end customer gets a vehicle with net power within the calculated and specified limits by Product Engineering. An inadequate compression ratio can greatly affect the engine performance and, in the same proportion, affect the end customer satisfaction, reliability and loyalty to the brand. The methodology to be presented in this work is based on the 3D virtual simulation software developed by Dimensional Control Systems Inc., the 3DCS® v.7, where through random combinations of dimensional variations of each component involved in the system it is possible to calculate the nominal compression ratio and the variation limits, simulate statistical values that actually happen in real life, and obtain a ranking of the contribution percentage of each variable to the total variation in compression ratio. Thus, it is possible to verify that the derivative compression ratio from the project meets the engineering specifications, as well as in cases of non-compliance, it is possible to input production data in the software for, through the ranking of variations sensitivity, identifying the key actuators and, in cases of corrective/containment actions, be as efficient as possible, avoiding to waste time and money by wrong design correction approaches.


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  • Accession Number: 01684458
  • Record Type: Publication
  • Source Agency: SAE International
  • Report/Paper Numbers: 2016-36-0287
  • Files: TRIS, SAE
  • Created Date: Mar 30 2017 9:30AM